Mercedes-Benz OM 457 LA User manual

OM 457 LA BlueTec® / OM 457 LA
OM 460 LA BlueTec® / OM 460 LA
Operating Instructions

Symbols
GWARNING
Warning notes make you aware of dangers
which could pose a threat to your health or
life, or to the health and life of others.
HEnvironmental note
Environmental notes provide you with infor-
mation on environmentally aware actions or
disposal.
! Notes on material damage alert you to
dangers that could lead to damage to your
vehicle.
iThese symbols indicate useful instruc-
tions or further information that could be
helpful to you.
XThis symbol designates an instruc-
tion you must follow.
XSeveral consecutive symbols indi-
cate an instruction with several
steps.
(Y page) This symbol tells you where you
can find further information on a
topic.
Y YThis symbol indicates a warning or
an instruction that is continued on
the next page.
Display This text indicates an indicator in
the display.

Welcome
Familiarise yourself with your engine system
and read the operating instructions before
you use the engine system. This will help you
to avoid endangering yourself or others.
The standard equipment and product descrip-
tion of your engine system may vary, depend-
ing on individual specifications. This is descri-
bed on the data card.
The engine systems are constantly updated
to be state of the art.
Mercedes-Benz reserves the right to make
changes to the following:
Rdesign
Requipment
Rtechnical features
Descriptions may therefore differ in individual
cases from your engine system.
4605843681 É4605843681ÇËÍ

Index ....................................................... 4
Introduction ........................................... 7
At a glance ........................................... 13
Safety ................................................... 29
Transport, installation ........................ 33
Operation ............................................. 37
Maintenance ........................................ 63
Decommissioning ............................... 75
Troubleshooting .................................. 79
Technical data ..................................... 93
Contents 3

A
AdBlue®/DEF
Components .................................... 18
Consumption ................................... 58
Gauge .............................................. 45
Important safety notes .................... 60
Refuelling ......................................... 60
Service product ............................... 71
ADM (FR (drive control) unit) ............. 14
B
Battery (vehicle)
Jump starting ................................... 83
Bio-diesel fuel
see FAME fatty acid methyl ester fuel
Bleeding the fuel prefilter with the
manual fuel pump ............................... 83
BlueTec®
Sensors ............................................ 18
Braking
Continuous brake ............................ 41
Engine brake .................................... 41
Retarder ........................................... 42
C
Capacities ............................................ 98
Care products ...................................... 72
Charge current .................................... 42
Checking the fluid level ...................... 38
Cleaning and care
Engine cleaning ................................ 73
High-pressure cleaning .................... 72
Notes on care .................................. 72
Cold-start aid ....................................... 61
Consumption
AdBlue®/DEF .................................. 58
Fuel .................................................. 58
Oil (engine) ...................................... 58
Continuous brake
Important safety notes .................... 41
Coolant
Mixing ratio ...................................... 68
Service product ............................... 68
Topping up ....................................... 39
Coolant additive .................................. 68
Correct use ............................................ 8
Corrosion inhibitor/antifreeze
agent .................................................... 68
D
Data card .............................................. 94
DEF/AdBlue®
see AdBlue®/DEF service products
Description of the engine ................... 14
Diagnostics connection ...................... 31
Diesel
Fuels ................................................ 68
Low outside temperatures ............... 70
Refuelling ......................................... 59
Sulphur content table ...................... 69
Dimensions .......................................... 95
Disposal of service products .............. 65
Driving mode
Idling speed ..................................... 42
Driving tips .......................................... 58
E
Electronic engine control
see Engine management
Electronic engine control unit ............ 42
Emergency gearshift
Using the emergency switch ............ 44
Emergency running program ................ 8
Engine
Capacities ........................................ 98
Cleaning ........................................... 72
Data ................................................. 95
Data card ......................................... 94
Data plate ........................................ 94
Modifying the power output ............... 8
Oil consumption ............................... 58
Operating data ................................. 97
Rectifying faults ............................... 86
Running-in period ............................. 58
Starting ............................................ 39
Stopping .......................................... 40
Engine brake ........................................ 41
Engine data .......................................... 95
Engine data card .................................. 94
Engine description .............................. 14
Engine idling speed ............................. 42
4Index

Engine management ........................... 19
Engine management control unit ...... 20
Engine model designation .................. 94
Engine oil
Consumption ................................... 58
For winter operation ........................ 65
Mixing .............................................. 67
Oil change ........................................ 66
Topping up ....................................... 67
Engine overview .................................. 15
Engine speed ....................................... 44
Exhaust gas aftertreatment ............... 21
Exhaust gas aftertreatment con-
trol unit ................................................ 21
F
FR (drive control) unit
see ADM
Fuel
Additives .......................................... 70
Consumption ................................... 58
Diesel ............................................... 68
FAME fatty acid methyl ester fuel .... 70
Refuelling ......................................... 59
Sulphur content table ...................... 69
Fuel grade ............................................ 69
Fuel prefilter
Draining ........................................... 82
Fuel system
Automatic bleeding .......................... 81
Manual bleeding .............................. 81
Fuses
Checking and replacing a safety
fuse .................................................. 83
Important safety notes .................... 83
G
Gauge
AdBlue®/DEF .................................. 45
Genuine Mercedes-Benz parts ............. 7
Getting started .................................... 80
H
High-pressure cleaning ....................... 72
I
Identification plate .............................. 94
Idling speed
Engine .............................................. 42
Indicator and warning lamps
BlueTec® exhaust gas aftertreat-
ment ................................................ 24
Installation ........................................... 34
Instrument cluster
Warning and indicator lamps ........... 23
J
Jump-starting ....................................... 83
M
Maintenance
Notes ............................................... 64
Mercedes-Benz Service Centre
see Qualified specialist workshop
MR control unit
see Engine management control unit
O
Oil (engine)
For winter operation ........................ 65
Oil change ........................................ 66
Scope of use .................................... 66
Oil pressure ......................................... 42
Operating data ..................................... 97
Operating instructions
General notes .................................. 10
Operating restriction
Off-highway ...................................... 26
On-highway ...................................... 24
Operating safety .................................. 30
Operating safety and registration
Changes in engine performance ........ 8
Implied warranty ................................ 8
Operational monitoring ...................... 42
Organisational measures ................... 31
Overview, sensors ............................... 17
P
Personnel ............................................. 31
Index 5

Poly-V-belt
Replacing ......................................... 90
Routing ............................................ 90
Preparing for starting operation
see Starting operation
Protection of the environment ............. 7
Q
Qualified specialist workshop ........... 10
R
Refuelling
AdBlue®/DEF .................................. 60
Fuels ................................................ 59
Requirements of the personnel ......... 31
Rev counter .......................................... 44
Roadside Assistance ........................... 80
Running the vehicle in ........................ 58
S
Safety and emergency running pro-
gram ....................................................... 8
Safety precautions .............................. 30
SCR frame module
see Exhaust gas aftertreatment
control unit
Service products
AdBlue®/DEF .................................. 71
Coolant ............................................ 68
DEF/AdBlue® .................................. 71
Diesel fuel ........................................ 68
Disposal ........................................... 65
Disposing of AdBlue®/DEF .............. 72
Engine oil ......................................... 65
FAME fatty acid methyl ester fuel .... 70
Fuel additives ................................... 70
General notes .................................. 65
Purity of AdBlue®/DEF .................... 72
Storing AdBlue®/DEF ...................... 72
Specialist workshop ............................ 10
Starting
see Starting (engine)
Starting (engine) .................................. 39
Stopping and switching off the
engine ................................................... 39
Sulphur content of fuel ....................... 69
T
Technical data
Dimensions ...................................... 95
Filling capacities .............................. 98
Operating data ................................. 97
Weights ............................................ 95
Tightening torques .............................. 99
Torque reduction ................................. 43
Transport .............................................. 34
W
Warning and indicator lamps
Electronics ....................................... 46
Weights ................................................ 96
Winter diesel ........................................ 70
Winter operation ................................. 61
6Index

Engine system
The OM 457-460 LA BlueTec® series of
engines only function as intended when used
in conjunction with the corresponding
exhaust gas aftertreatment unit. Therefore, in
these Operating Instructions, the term
"engine system" refers to the engine and the
exhaust gas aftertreatment unit.
Protection of the environment
HEnvironmental note
Daimler AG has a declared policy of compre-
hensive environmental protection.
The objectives are to use the natural resour-
ces which form the basis of our existence on
this planet sparingly and in a manner which
takes the requirements of both nature and
humanity into account.
You too can help to protect the environment
by operating your vehicle in an environmen-
tally responsible manner.
Information and notes on driving in an envi-
ronmentally responsible and fuel-saving man-
ner can be found in the "Operating notes"
section (Y page 58).
Assembly equipment
These Operating Instructions describe all
models and all standard and optional equip-
ment available for your engine system at the
time of publication of the Operating Instruc-
tions. Country-specific deviations are possi-
ble. Note that your engine system may not be
fitted with all features described. This also
applies to safety-relevant systems and func-
tions. Therefore, the equipment on your
engine system may differ from certain
descriptions and illustrations.
All of the components in your engine system
are listed in the data card of your engine sys-
tem. Data card (Y page 94).
Please contact a Mercedes-Benz, MTU or
MTU-authorised Mercedes-Benz Service
Centre if you have any questions about equip-
ment or operation (see addresses in the pub-
lication details on the rear inside cover).
RMercedes-Benz recommends, for on-high-
way applications, that you use a Mercedes-
Benz Service Centre.
RMTU recommends, for off-highway applica-
tions, an MTU partner or MTU-authorised
Mercedes‑Benz partner.
Genuine Mercedes-Benz parts
HEnvironmental note
Daimler AG also supplies reconditioned
assemblies and parts which are of the same
quality as new parts. For these, the same war-
ranty applies as for new parts.
If you use parts which have not been
approved by Mercedes-Benz, the operational
safety of the engine system may be jeopar-
dised. This could lead to malfunctions in
safety-relevant systems. Use only genuine
Mercedes-Benz parts or parts of equal qual-
ity. Only use parts that have been approved
for your engine type.
Mercedes-Benz checks genuine Mercedes-
Benz parts for:
Rreliability
Rsafety
Rsuitability
Despite ongoing market research, Mercedes-
Benz is unable to assess other parts.
Mercedes-Benz therefore accepts no respon-
sibility for the use of such parts in Mercedes-
Benz vehicles, even if they have been officially
approved or independently approved by a
testing centre.
In Germany, certain parts are only officially
approved for installation or modification if
they comply with legal requirements. This
also applies to some other countries. All gen-
uine Mercedes-Benz parts meet the approval
Introduction 7
Z

requirements. The use of non-approved parts
may invalidate the vehicle's general operating
permit.
This is the case if:
Rthey result in a change to the vehicle type
from that for which the vehicle's general
operating permit was granted
Rthey pose a possible risk for road users
Rthey adversely affect the emission or noise
levels
You can find more information on recommen-
ded conversion parts and accessories, as well
as permitted technical modifications at any
Mercedes-Benz, MTU or MTU-authorised
Mercedes-Benz Service Centre (Y page 10).
Always state the engine number when order-
ing genuine Mercedes-Benz parts. You can
find the engine number on the identification
plate of your engine. You can also find the
numbers on the data card (Y page 94).
Modifying the engine output
! Increased power could:
Rchange emission levels
Rcause malfunctions
Rlead to consequential damage
The operating safety of the engine cannot
be guaranteed in all situations.
Any tampering with the engine management
system in order to increase the engine power
output will lead to a loss of warranty entitle-
ments.
Safety/emergency running program
The engine is equipped with an electronic
engine management system that monitors
the engine and has a self-diagnostic system.
If the electronic control system detects a mal-
function, one of the following measures is
automatically implemented after an appraisal
of the malfunction:
Rfaults during operation are indicated by the
corresponding warning lamp (Y page 46).
Rin conjunction with the electronic engine
management system, fault codes with addi-
tional information can be shown on a dis-
play.
Rthe system switches to a suitable backup
function for the continued, albeit restric-
ted, operation of the engine. This includes
torque and engine speed limitation, for
example, as well as road speed limitation or
constant emergency running speed.
Correct use
The engine system may only be installed as
contractually specified.
The manufacturer of the end product is
responsible for the correct installation of the
engine and the exhaust gas aftertreatment
system in the overall system.
The engine and the exhaust gas aftertreat-
ment system may not be modified. If the
engine is modified, Mercedes-Benz and MTU
do not accept responsibility for any damage
arising as a result.
Correct use of the engine system also
requires adherence to the instructions in
these Operating Instructions. This also
requires compliance with the maintenance
intervals and the professional execution of
maintenance work. Please observe the Work-
shop Information System (WIS) (Y page 10).
Implied warranty
A well-developed network of Mercedes-Benz,
MTU and MTU-authorised Mercedes-Benz
Service Centres is available to carry out main-
tenance work.
8Introduction

These Mercedes-Benz and MTU or MTU-
authorised Mercedes-Benz Service Centres:
Rhave special equipment and tools as well as
specialists who receive continuous training
Rguarantee that your engine system is
repaired and maintained thoroughly and
expertly
Rcarry out all repairs related to implied war-
ranty
Rcarry out all maintenance work expertly
Rconfirm in the Maintenance Booklet that
the maintenance work has been carried out
at the required time
Rhandle implied warranty claims that are
admissible according to the sales contract
Please observe the instructions and recom-
mendations as well as the maintenance serv-
ices in the Maintenance Booklet. Please
observe these instructions even if you let a
third party use and care for your vehicle. This
is the only way to ensure that you do not lose
your entitlements.
If the prescribed maintenance work is not
carried out, claims can only be decided after
the manufacturer has inspected the claim.
During the implied warranty period, have the
prescribed maintenance service for your
engine system carried out as follows:
Rregularly
Rpunctually
Rat a qualified specialist workshop which
has the necessary specialist knowledge
and tools to carry out the work required
Mercedes-Benz recommends that you use
a Mercedes-Benz, MTU or MTU-authorised
Mercedes-Benz Service Centre. In particu-
lar, work relevant to safety or on safety-
related systems must be carried out by a
qualified specialist workshop.
If there are legal requirements on emission
control, please note that:
Rmaintenance on the engines must be car-
ried out according to specific regulations
and using special measuring devices
Rit is prohibited to modify or tamper with
components relevant to emissions
All Mercedes-Benz and MTU or MTU-author-
ised Mercedes-Benz Service Centres are
familiar with the relevant regulations.
Maintenance work does not include repair
work. Issue a separate order for repair work.
You can obtain further information on the
maintenance of your engine system from any
Mercedes-Benz, MTU or MTU-authorised
Mercedes-Benz Service Centre.
Stored data
Several of the electronic components in your
engine system contain data memories.
These data memories temporarily or perma-
nently store technical information about:
Rthe engine system state
Revents
Rmalfunctions
In general, this technical information docu-
ments the state of a component, a module, a
system or the surroundings.
This includes, for example:
Roperating conditions of system compo-
nents, e.g. fluid levels
Rthe vehicle's status messages and those of
its individual components, e.g. speed,
deceleration in movement, accelerator
position
Rmalfunctions and defects in important sys-
tem components
Rthe vehicle's reactions and operating sta-
tuses in special driving situations
Rambient conditions, e.g. outside tempera-
ture
Introduction 9
Z

This data is exclusively technical in nature
and can be used to:
Rassist in the detection and rectification of
faults and defects
Ranalyse vehicle functions, e.g. after an acci-
dent
The data cannot be used to trace the vehicle's
movements.
When you use one of the available services,
technical information may be read from the
event data memory and fault data memory.
Services include, for example:
Rrepair services
Rservice processes
Rimplied warranty and guarantee cases
Rquality assurance
The information is read out by employees of
the service network (including manufactur-
ers) using special diagnostic testers. Further
information is available there if required.
After a fault has been rectified, the informa-
tion is deleted from the fault memory or is
continually overwritten.
Qualified specialist workshop
A qualified specialist workshop has the nec-
essary specialist knowledge, tools and quali-
fications to carry out the work required on the
engine to a professional standard. This is par-
ticularly applicable to work relevant to safety.
Observe the notes in the Maintenance Book-
let.
Always have the following maintenance work
carried out at a qualified specialist workshop:
Rwork relevant to safety
Rservice and maintenance work
Rrepair work
Rmodifications as well as installations and
conversions
Rwork on electronic components
RMercedes-Benz recommends, for on-high-
way applications, that you use a Mercedes-
Benz Service Centre.
RMTU recommends, for off-highway applica-
tions, an MTU partner or MTU-authorised
Mercedes‑Benz partner.
Further applicable documents
These Operating Instructions describe all
models, as well as all standard and optional
equipment of your engine system which are
part of the scope of delivery of Daimler AG.
The installation of the engine system into the
vehicle/device may require additional oper-
ating instructions adapted to the vehicle/
device and the appropriate use thereof. These
additional operating instructions will be pro-
vided by the vehicle/device manufacturer.
The additional operating instructions will
describe, in particular, the functions specific
to the installation and operation, the use of
such functions as well as warning and control
mechanisms.
To use the engine correctly, you also require
the Maintenance Booklet.
For US-certified off-highway engines you also
require the "Emission Warranty" supplement.
Please also observe the information con-
tained in the vehicle or the equipment oper-
ating instructions (manufacturer of the end
product). Always keep these documents
together with the engine, vehicle or equip-
ment. These documents should be passed on
to the new owner if you sell the engine, vehi-
cle or equipment.
When carrying out maintenance work, you
require access to the Workshop Information
System (WIS) via the Internet. This access is
subject to a fee.
Current information on the system and prices
can be found at this web address: http://
service-parts.mercedes-benz.com. Click on
"EPC, WIS/ASRA" in the "Service and parts
information" tab and then on "WIS".
10 Introduction

You can log in by clicking on "Register" on the
right-hand side.
Introduction 11
Z

12

General information ............................ 14
Engine overview .................................. 15
Sensors overview ................................ 17
Electronic engine management ......... 19
BlueTec® exhaust gas aftertreat-
ment ..................................................... 21
Warning and indicator lamps ............. 23
13
At a glance

General information
The engine is a four-stroke, water-cooled die-
sel engine with direct injection.
The six cylinders are arranged in a row. Each
cylinder has two inlet and two outlet valves.
Each cylinder has its own fuel injection pump
(unit pump) with a short high-pressure fuel
injection line to the multi-hole nozzle at the
centre of the combustion chamber. The unit
pumps sit directly in the crankcase and are
driven by the camshaft.
The engine is equipped with exhaust gas tur-
bocharger and intercooler as standard. The
engine may include an engine brake (airbrake
and constantly open throttle) as optional
equipment.
It is a low-emission engine. Start of injection,
injection duration and injection quantity are
controlled entirely electronically.
BlueTEC® exhaust gas aftertreatment
The engines meet the requirements of the
relevant emissions level and are correspond-
ingly certified. Compliance with emissions
laws and regulations is a condition of the
operating permit for the vehicle/equipment.
The BlueTEC® exhaust gas aftertreatment
unit is characterised by the following tech-
nologies:
Rselective catalytic reduction (SCR) with
ammonia slip catalytic converter
Rthe diesel oxidation catalytic converter
(DOC)
Engines with BlueTEC® exhaust gas after-
treatment must be operated with AdBlue® or
DEF in order to meet the emissions laws and
regulations. The operating permit is invalida-
ted if the vehicle/equipment is operated
without AdBlue®/DEF. Failure to use
AdBlue® or DEF during operation may be a
statutory or regulatory offence in certain
countries. Special concessions granted
either at the time of purchase or to reduce
operating costs of the vehicle/equipment,
e.g. reduced taxes or tolls, may also be ren-
dered retroactively invalid. This may be the
case in the country of registration. Or also in
another country where you operate the vehi-
cle/equipment.
14 General information
At a glance

Engine overview
:Poly-V-belt
;Fuel pump
=Thermostat housing
?Fuel filter
AOil filter
BCylinder head cover
CStart/Stop button
DCharge-air distributor
ECharge-air pipe from the charge-air cooler
FCrankcase ventilation system
GEngine control unit (MR)
HAir compressor
IPower-steering pump
JDipstick
KEngine oil filler neck
Engine overview 15
At a glance

:Alternator
;Starter motor
=Exhaust gas turbocharger
?Exhaust manifold
ACoolant pump
BPoly V-belt tensioning device
16 Engine overview
At a glance

Sensors overview
Sensors, general
:Engine oil pressure and temperature sensor
;Charge-air pressure/temperature sensor
=Camshaft position sensor (on camshaft gear)
?Crankshaft position sensor (on flywheel)
ACoolant temperature sensor
BEngine oil level sensor
CFuel temperature sensor
Sensors overview 17
At a glance

AdBlue®/DEF components
BlueTec® sensors, overview
:NOX sensor
;Metering unit
=Exhaust aftertreatment unit
?Temperature and humidity sensor (air filter, clean air side)
AValve preheating, AdBlue®/DEF system
BExhaust gas temperature sensor (inlet)
CExhaust gas temperature sensor (outlet)
DExhaust gas aftertreatment control unit
ESupply unit
FAdBlue®/DEF filter
GAdBlue®/DEF tank
18 Sensors overview
At a glance